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NTPC Ltd(Corporate Operation services)
Date: 03-12-08
Sub : Report on Sipat - II : For commissioning of unit # 5
1. LHS milling system
2. PA fan # B , FD fan # B & ID fan # B trial run
3. TDBFP # A & B trial run
4. ESP passes C & D readiness
5. Mill rejects handling system
6. Erection of FG I/L duct for ESP C & D passes
7. ESP C & D pass fly ash handling system
8. Wall blowers and LRSBs commissioning
9. Condensate polishing unit
10. CPU regeneration system
11. Boiler lift
Put up for kind persual.
AGM(OS)
The undersigned was on tour from 27/11/08 to 29/11/08 stationed at Sipat STPP to review the unit # 5 commissioning activities . BLU of Unit # 5 has been planed on 12-12-08 to achive full load generation and subsequent activities . The erection completion and commissioning of the following systems is pending (Detailed list of pending activities has been enclosed).
Asok kumar Das Sr Manager (OS)
Annexure
NTPC - Sipat stage II (2*500MW) - Status of unit # 5 as on 30th Nov-08
Milestones achieved
Target for BLU to achieve 500 MW 12th Dec-08
System /Equipments ready
Sl No Area Equipments1 Mills Mill A- D proven , Mill # E ready for operation2 Fans FD fan # A , ID fan # A & PA fan # A3 APHs Pri APH # A , Both Sec APH 4 ESP pass Pass # A & B 5 SADC & burner tilt Remote operation ready6 Safety valves & ERVs7 Cooling system ACW(A/B/C) , SGECW(A/B), TGECW(A/B/C)8 LPHs LPH 1/2/39 Safety valves
10 Ash handling sy BA sy( A,B grinder ) , FA for ESP pass A, B11 CW & CT sy
Status of balance system/ Equipments
SL NO Equipment Present status Tar date
1
LHS millsMill # F 5th Dec-08Mill # G 10th Dec-08Mill # H 15th Dec-08Mill # J Sole plates erected 20th Dec-08Mill # K No erection activity started 20th Dec-08
2
Feeders for LHS mill Mill # F Erection not started 7th Dec-08Mill # G Erection not started 10th Dec-08Mill # H Erection not started 14th Dec-08Mill # J Erection not started 20th Dec-08Mill # K Erection not started 20th Dec-08
3
Coal pipings for LHS mills Mill # F 120/ 126 pipes completed 10th Dec-08Mill # G 111/122 pipes complted 10th Dec-08Mill # H 92/117 pipes complted 10th Dec-08
Mill # J 15th Dec-08
Mill # K 15th Dec-08
4
Bunkers for LHS mills Mill # F Loading clearance givenMill # G Ready for inspectionMill # H Ring beams / plan bracings erection in progress 5th Dec-08Mill # J SS cone welding in progress in feeder floor 15th Dec-08
1. Test synchronised with oil on 13.08.08 2. Coal firing on 10.11.08 3. 200 MW achieved on 12.11.08
1. Erection completed upto MDV, 2. Rollers / LO piping / Motor alignment / tray works / cabling balance
73 /114 pipes complted, front required from mill side
71/116 pipes complted, front required from mill side
4
Mill # K SS cone welding in progress at zero meter 20th Dec-08
SL NO Equipment Present status Tar date
5
Fans
FD fan # B trial 7th Dec-08
PA fan # B trial 7th Dec-08
ID fan # B trial 14th Dec-08
Pri APH # B
6
Balance DuctingDuct ready , ATT is to be done 15 nos NMEJs to be fixed
Balance external ducting (BOF to ESP)
ESP # C pass 10th Dec-08
ESP # D pass 20th Dec-08
7
Pending InsulationsPA fan # A Dish duct partially pending
FD fan # A Dish duct lower plane pending
LHS air duct Cold + hot duct pending
FD fan # B Disc duct pending
ESP D pass BOF to ESP + ESP + ESP to ID fan
8
BFPs
TDBFP # A pump trial Put on barring on 14-11-08
2nd Dec-08Solo run & pump trial pending
TDBFP # B pump trial 15th Dec-08
9
ESP
# C pass ATT done , O/L duct & gates readyField charging on 05-12-08
# D passATT done , O/L duct & gates readyField charging on 20-12-08
10 Wall blowers (88 nos)
11
Spray SH spray Remote commissioning done
RH spray
12 CPU # 5
13 CPU regeneration PLC commissioning in progress 4 th Dec-0814 Mill reject handling sy Pyrite hopper of RHS mills erected
1. Motor trial run taken 2. LO flushing started on 20/11 & comp by 30/11 3. Blade fixing pending
Blade fixing , motor trial , LO lines flushing pending
1. Motor alignment in progress , LO pump trial done 2. LO flushing in progress since 27/11 3. Power cabling from VFD Xfmr to SWGR prnding , motor trial
1. LO line flushing , motor trial run , completed 2. Air motor trial run , soot blower & dampers commissioning pending
LHS PA cold and hot air duct
O/L duct completed , I/L duct erection in progress
Insulation material problem
LO flusing started on 27/11/08 , compl by 07/12/08
Instrumentation , putting on barring , solo run & pump trial pending
Erection completed , dry run and commissioning of remote operation pending
Line erection done / steam blowing done / Flow measurement element to be installed.
1. Vessels erection done , pipings erection in progress 2. Instrumentation and commissioning pending
Exp by 30-12-08
SL NO Equipment Present status Tar date
15
Ash handling sy
BA system
ESP passes ESP A & B pass commissioned
#C pass
Ash evacuation pipings erection in progressVacuum pump , collecting tower erected
#D pass
Ash handling series Series A & B ready
Series # A Water trial completed
Series # B Motor trial done , pump trial pending
16 Boiler lift Not installed
Grinder A,B ready with disposal line , Grinder C,D installed & to be commissioned , disposal line of grinder C & D erection in progress (Tar 30.11.08)
ECO & APH ash evacuation
ECO & APH of LHS completed , RHS of APH in progrss
Instrumentation ,Commissioning of MHV's,vacuum pump pending1. Erection of ash evacution pipings & valves ,collecting tower and Vacuum pump pending 2. Instrumentation ,Commissioning of MHV's,vacuum pump pending
Asok Kumar Das SR Manager(OS)
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
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Sipat unit # 5 Turbine bearing temp and vibrationUnit # 5 unit # 4
Load 210 MW Load 282 MW Load 500 MW Load 500 MW
Brg no Axis
1 X 19.89 86.6578.84
19.1 74.779
18.8 6179
12.6 6372
Y 15.33 117.79 13.8 106 14.5 92 17 29
2 X 8.35 7274.7
12.9 72.575
11.09 7375
8 8074
Y 12.5 158.04 10.4 164 15.52 151 9.8 24
3 X 16.74 75.0188.4
18.7 25.7888
17.16 5371
11 3390
Y 23.05 98.7 20.7 83.9 26.68 92 14 26
4 X 35.7 59.8188.45
33.3 55.288
22.8 6089
24 8090
Y 38.01 38.64 36.6 43.9 37.8 45 27 83
5 X 66.28 46.7776.11
50.67 52.677
49.18 5877
31 7874
Y 8.86 73.03 14.2 67.2 20.28 73 56 128
6 X 24.41 18.2876.96
24.8 25.477
20.8 3578
18 5877
Y 21.87 35.34 26.3 36.1 24.47 48 17 65
7 X 25.82 87.0663.49
22.07 73.464
25 7164
15 9771
Y 30.29 58.07 25.03 56.5 24.6 59 19 90
Brg vibn
Shaft vibn
Max brg temp
Brg vibn
Shaft vibn
Max brg temp
Brg vibn
Shaft vibn
Max brg temp
Brg vibn
Shaft vibn
Max brg
temp
Status of Auto Loop of Sipat # 5ABB station C&I system
Sl No Description Status Remarks
1 Furnace draft Yes Auto
2 Drum level low Yes Proven in auto
3 Drum level high Yes Auto
4 PA header pr Yes Auto
5 Hotwell level control Auto
6 D/A level Yes Auto
7 D/A pressure Yes Man
8 GSC min R/C Yes Proven in auto
9 CEP R/C Yes Proven in auto
10 LPH level Yes Auto
11 HPH level Yes for HPH 6B/5B HPH 6A/5A not avl
12 TG/SG ECW DP Yes Manual
13 Mill air flow Yes Mill A to H Mill J & K not ready
14 Mills outlet temp Yes Mill A to H Mill J & K not ready
15 Air flow master Yes Proven in auto
16 Fuel flow master Yes Proven in auto
17 SH spray Yes Auto
18 RH spray Yes Proven in auto
19 Boiler follow mode Yes Proven in auto
20 CMC Yes Proven in auto
Readiness from C & I side ID fan kept in
manual due to single channel operation
Normal M/U ready
Put in auto for 1hr 30 mins
BHEL C&I system
1 Yes Auto
2 Turbine lub oil temp Yes Auto
3 Primary water temp Yes Auto
4 Cold gas temp Yes Auto
5 Control fluid temp No Man
6 HPBH & LPBP Yes Proven in auto
7 Turbine EHC Yes Auto
8 TDBFP-A seal /Leak steam pr Yes Auto9 Fuel oil pressure Yes Proven in auto
10 Atomising steam pressure Yes Proven in auto11 SADC Yes Auto
12 Aux PRDS MS & CRH No Man
Seal steam / Leak steam system
MS PRDS not charged
NTPC Ltd(Corporate Operation services)
Date 23-12-08
Sub : Report on Sipat - II : For commissioning of unit # 5
1. LHS milling system
3. TDBFP # B
4. ESP pass "D" readiness
5. Mill rejects handling system
6. ESP D pass fly ash handling system
7. Wall blowers and LRSBs commissioning
8. Pending insulation of air + FG duct + ESP , FW pipes + HPHs' drips , SH & RH spray lines
8. Ash slurry series A & B
9. Condensate polishing unit
9. Coal tranportation thro' MGR
11. Boiler lift
Put up for kind persual.
AGM(OS)
The undersigned was on tour from19/12/08 to 22/12/08 stationed at Sipat STPP for unit # 5 commissioning activities .Unit is presently running at 300 MW load with 5 mills (RHS).COD of Unit # 5 has been planed on 31-12-08 . The erection completion and commissioning of the following systems is pending (Detailed list of pending activities has been enclosed).
Asok kumar Das Sr Manager (OS)
NTPC - Sipat stage II (2*500MW) - Status of unit # 5 as on 22 th Dec-08
Milestones achieved
COD 31st Dec-08
System /Equipments ready
Sl No Area Equipments1 Mills Mill A- E proven
2 Fans
3 APHs Both Pri APH , Both Sec APH 4 ESP pass Pass # A, B ,C5 SADC & burner tilt Remote operation ready6 Safety valves & ERVs7 Cooling system ACW(A/B/C) , SGECW(A/B), TGECW(A/B/C)8 LPHs LPH 1/2/39 Ash handling sy BA sy( All 4 grinder ) , FA for ESP pass A, B & C Series # C & D
10 BFPs MDBFP & TDBFP A
10 CW & CT sy11 CPU regeneration
Status of balance system/ Equipments
SL NO Equipment Present status Tar date
1
LHS mills
Mill # F 26th Dec-08
Mill # G 25th Dec-08
Mill # H 25th Dec-08
Mill # J Erection completed upto MDH 25th Dec-08Mill # K Erection completed upto MDH 25th Dec-08
2
Feeders for LHS mill Mill # F Feeder calibration done Mill # G Feeder calibration done
Mill # H 25th Dec-08
Mill # J 25th Dec-08Mill # K 25th Dec-08
1. Test synchronised with oil on 13.08.08 2. Coal firing on 10.11.08
Both ID fans , FD fans and PA fans (ID fan # B ch -2 not available/VFD xfrm damaged / being shifted from KhSTPP)
1. Mill bearing (lower) damaged during trial run ( After 15 mins running) 2. mill dry run and CAF test pending1.Mill boxed up ,LO flushing completed. 2.Motor alignment & cabling in progress 3. motor trial exp on 24-12 / mill dry run / CAF test pending1. Mill boxed up .Motor trial done. LO flushing in progress 3. Mill dry run & CAF pending
Feeder / outlet pipe / gate erection done . Feed pipe / bunker outlet gate erection / feeder calibration pending
SL NO Equipment Present status Tar date
3 Coal pipings for LHS mills : Coal pulling done & supports in progress
4
Bunkers for LHS mills Mill # F Loading clearance givenMill # G Loading clearance given on 01-12-08Mill # H Loading clearance given on 10-12-09Mill # J SS cone erected & welding in progress 25th Dec-08Mill # K SS cone erected & welding in progress 25th Dec-08
6
Balance Ducting
13/ 15 nos NMEJs to be fixed
Balance external ducting (BOF to ESP)ESP # C pass
ESP # D pass 25th Dec-08
7
Pending Insulations
Boiler
PA fan # A Dish duct partially pending
FD fan # A Dish duct lower plane pending
LHS air duct Cold + hot duct pending
FD fan # B Disc duct pending
ESP D pass BOF to ESP + ESP + ESP to ID fan
TDBFP # A BP + MP (suction & discharge line : partially)
SH spray Line & spray station
RH spray Line & spray station
HPHs FW lines + drip lines
8
BFPs
TDBFP # B pump trial 30th Dec-08
9
ESP
# C pass To be taken in service after rectification of fields.
23-12-0830 % insulation pending
# D passATT done , O/L duct & gates ready
30-12-08Field charging / insulation pending
10 Wall blowers (88 nos) Erection completed . Dru run of 46 nos done
11
Spray SH spray Put on auto
RH spray
12 CPU # 5
13 CPU regeneration PLC commissioning
PA Duct NMEJs LHS
C pass charged.30 % Insulation pending
1. 2/2 boxex erected 2. 2nos NMEJ erection , welding of duct /ATT/ insulation balance
Corners firing zone (high density insulations to be put)
Insulation material received / work in progress
Steam blowing of line , LO flusing completed , steam piping / feed water piping in progress
Pump alignment , Instrumentation , putting on barring , solo run & pump trial pending
One line each stream ready for manual operation
1. Vessels erection done , pipings erection in progress( resin transfer line , DM water line pending) 2. Instrumentation and commissioning pending
Exp by 30-12-08
SL NO Equipment Present status Tar date
14 SWAS Pipings in progress / Instrument cabling , Instrumentations and commissioning pending
SL NO Equipment Present status Tar date
15 Mill reject handling sy
16
Ash handling syBA systemBA piping 4 MS lines ready
Clinker grinder & flap gate All 4 commissioned
Completed
ESP passes ESP A & B pass commissioned
#C pass
#D pass
Ash handling series Series C & D ready
Series # A Erection done / Motor & pump trila pending
Series # B
A/B ADL
17 LHS tripper
18 MGR
19 Boiler lift Not installed
Pyrite hopper of RHS mills erected / for LHS mills pending
ECO & APH ash evacuation
Ash evacuation pipings erection in progress(Laterals 250 NB, strainers , pipes of sizes 150 NB, 200 NB , 25 NB urgently required)
Vacuum pump commissioned, collecting tower erected
Instrumentation ,Commissioning of MHV's,vacuum pump pending1. Erection of ash evacution pipings & valves ,collecting tower and Vacuum pump pending 2. Instrumentation ,Commissioning of MHV's,vacuum pump pending
Motor trial done , pump B1 trial done . Trial for PP B2 & B3 pending
B line completed ; A > 10 joints pending for rail culverts
27A - Fire has damaged the belt. Belt restoration work to start on 22.12.08. Empty rack run done upto SILO. Delay in awarding in contracts for loading in SILO from Coal India end.
Asok Kumar Das SR Manager(OS)
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
Put up for kind persual.
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Sipat # 5 Observation prior to full load operation
Sl No Area
1 24 meter cable gallery 2 8.5 meter LPHs + BFP exhaust area 3 Boiler "0" meter Full of debris + scrap + construction eqpts
4 Mills area 5 ESP area drains around incomplete 6 PA fan area Drains in front of PA fans incomplte
78 ESP control room Approach to the stair case incomplte
Lot of opennings in the control room9 Generator seal oil system Full of debris
10 Oil station tray Full of debris 11 Boiler different floor Debris + scrap
Drains not complete + complete drains are full of debris
Approach road inbetween PA fans and ESP incomplete
Sipat # 5 : Activity chart towards full load
Date Time Activity Remarks 17-12-08 15:58 BLU18-12-08 18:41 Syn19-12-08 15:54 unit triped "Generator inter turn protection" /Bus duct PT loose 19-12-09 16:19 BLU19-12-10 Syn20-12-08 15:57 Unit triped
Sipat # 5 : Problems faced in the Journey towards full load
Sl No Equipment Problem faced Solution / Action taken
1 CW pp # 4 P/S module replaced
2 TDBFP # A Attended
3 ID fan B Ch 2 VFD Xfrm burnt VFD Xfrm being shifted from KhSTPP # 7
4 Mill # F Brg replaced
5 Mill # D Pulley replaced + belt replaced
6 Mill # E Coal dust lkg from mill top Tightened
7 TDBFP # A Diaphragm replaced
8 Mill # B Feeder tripping w/o alarm
9 Sec APH # B
10 Generator bus duct PT PT loose / tightened
11 UAT # 5B Syn permissive not coming
12 Mill # G Vibration high Roller setting done
13 Wall blowers Gasket replaced with original one
14 PA fan A I/O card problem Replaced
15 TDBFP # A Replaced
16 MS silica high (35 ppb ) CPU not available
Triped (first out S1 & S2 energised)
Oil lkg from from BP(NDE) return oil line & MP(NDE) RTD
Bearing damaged during mill trial ( lower brg)
Feeder beld damaged , Idler pulley damaged
Diaphragm dameged ( Unit triped on Cond vac low)
Fault in the Control supply (Neutral to ground )
Rotor stoppage alarm not coming
Unit triped on generator interturn protection
Staem line safety valve flange gasket leakage (twice)
BP suction strainer gasket ruptured